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IMD film in-molding
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1 The Concept
In-mold injection molding decoration technology namelyIMD（In-Mold Decoration），IMDIt is a popular surface decoration technology in the world at present. It is mainly used in surface decoration and functional panels of household electrical appliances. It is commonly used in exterior parts such as mobile phone window lenses and housings, consumer electronic product housings, washing machine control panels, refrigerator control panels, air conditioning control panels, automobile instrument panels, rice cooker control panels, etc.
Conceptually speakingIMDis a general term, containingIMR,IML,INS（IMF）。
2. Process introduction
（1）IMR
IMRIs a roll to roll process, can be fully automatic production. It is especially suitable for decorative panels and functional panels on the outer surface of products. At present, it is widely used in notebooks, early mobile phones, home appliances and automobiles.
● Diaphragm
IMRThe process is characterized by the outermost layer of the diaphragm as a release film, generally.PETMaterial. After the production is completed, the product is separated from the base film, which can form a roll-to-roll continuous production.
● Plane effect
●Other decorative effects
Weiliang Optics provides customers with thermal UV dual-curing transfer coating (or UV transfer adhesive). After the first stage of thermosetting, the surface is dry and can be rolled up, and the stretching rate is adjustable by 150-20%. After the second stage of UV curing, the hardness is further improved, and the PET substrate can reach 2H. At the same time, it has good wear resistance, which solves the performance defects of low hardness and non-wear resistance of IMR process coating.
（2）IML
IMLEnglish isIn-Mold Label(partially madeIn molding Lamination), generally called in-mold insert injection molding, in-mold labeling, etc.(Low degree of stretching)At present, this technology has been widely used in home appliances, automobiles, medical electronics and other industries. Such as common air conditioners, washing machinesIMDControl panel, sweeping robot cover, car integrated display cover, central control panel, etc.
● Diaphragm
The injection molding process of in-mold insert is characterized by a hardened transparent film on the surface, a printed pattern layer in the middle and a plastic layer on the back. As the ink is sandwiched in the middle, the product can prevent the surface from being scratched and abraded, and can keep the color bright and hard to fade for a long time. withIMRThe difference is thatIMLThe whole diaphragm will remain on the surface of the product.
IMLThe film substrate can be, depending on the application scenario and use requirements.PET,PMMA,ABS,PC,PMMAOrPC PMMA,ABS PMMA. But the application in the automotive industry is generally PMMA ABS,PC,PC PMMA.
IMLDistinguish in processingIMRA very important step is the diaphragm molding. Generally speaking, there are two molding methods: hot pressing and air high pressure: relatively speaking, the air high pressure effect is better, and the damage to the appearance of the diaphragm is small.
At present, most of the in-film injection molding processes on the market are IML, which has the advantages of low cost, rich surface effect, excellent performance, mature technology, etc. However, for the demand scenarios of high tensile, high hardness and high wear resistance, hardening needs to be done again. Although the performance can meet the requirements, the original intention of no spraying in-film injection molding has been achieved. According to the market demand, Weiliang Optics has introduced a thermal UV dual-curing coating solution. A thermal UV dual-curing and hard layer is made on the surface of IML diaphragm. The coating can be rolled up after thermosetting and has high tensile strength. After UV curing, high hardness and high wear resistance can be realized, which well solves the deficiency of IML in high tensile scenes.
（3）INS（IMF）
INSinlay injection molding process,It is a proper term for high-stretch mold injection in the automotive industry. This process is the use of hot plastic molding or high pressure molding method, the transfer of goodABSFilm orABS PMMAThree-degree stretching, and then according to the product shape cut insert, and then the insert is accurately placed in the injection mold cavity, injection molding.
There are also some manufacturers calledIMF:In-Mold Forming, refers to the high stretchIML.
INSMain products: automotive interior trim products, dashboard trim, auxiliary instrument panel, door trim, rear armrests, signs, etc;
●Diaphragm
INSThe diaphragm isABSFilm orABS PMMA, generally thick0.5mm,PMMAprobably accounted25%Right and left0.125mm. BecausePMMARelativeABSTo have better scratch resistance, currently in the car interiorABS PMMAThe composite diaphragm is more.
INSThe diaphragm is similarIML, also need to first diaphragm molding. Because the material isABS/ABS PMMAIts molding generally adopts air pressure molding.
●INSdiaphragm coating structure
INSThe whole from the processIMLbasically the same,The substrate will remain on the injection molded parts, and the surface is PMMA. Under high tensile conditions, the balance of hardness and wear resistance is achieved,It is mainly in the interior of automobiles, but its performance in dimensional stability and hand sweat resistance is still insufficient. Therefore, INS diaphragm is mainly imported. The imported diaphragm has been hardened on the surface. Weiliang Optics is based on the existing technology platformA thermal UV dual curing coating solution is developed. A thermal UV dual curing and hard coating is made on the surface of INS diaphragm. The thermosetting coating can be rolled up and has high tensile strength. After UV curing, high hardness and high wear resistance can be realized. The substrate can be replaced by PC, which has better performance in dimensional stability, flame retardancy and tensile properties. PMMA ABS scheme can also be used to improve hardness and hand sweat resistance..
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